PILOT V8

OPERATOR MANUAL
PUBLICATION ISSUED BY:

Via Kennedy, 24 - 10019 STRAMBINO (TO)

Tel.: +39 0125 63 68 11
Fax.: +39 0125 63 68 99
e-mail: [email protected]
Web site: http://www.seica.com

Copyright © 2013
All rights reserved

Microsoft Windows is a registered trademark of Microsoft Corporation

Document code: MA-VI-PIV80PEN-02

Release software: VIVA Rel. 2.2.0.
Date of issue: 2013 - 10 - 10

Seica S.p.A. reserves the right to change the technical specifications without notice.

(*) The cover image is for illustration purposes only

 contents

CONTENTS

CONTENTS ........................................................................................................................................ I
LIST OF FIGURES .......................................................................................................................... II
1. GENERAL ...............................................................................................................................1-1
1. 1 USERS OF THIS MANUAL ............................................................................................1-1
1. 2 REFERENCE DOCUMENTATION ................................................................................1-1
1. 3 SYMBOLS ........................................................................................................................1-1
1. 4 SAFETY RECOMMENDATIONS ..................................................................................1-3
1.4.1 PROJECT CRITERIA ......................................................................................................1-3
1.4.2 SAFETY DEVICES ...........................................................................................................1-3
1.4.3 WARNINGS AND RECOMMENDED BEHAVIOR .........................................................1-5
1.4.4 RECOMMENDED USE OF THE SYSTEM .....................................................................1-6
1.4.5 IMPROPER USE..............................................................................................................1-6
1.4.6 RESIDUAL HAZARDS .....................................................................................................1-6
1.4.7 WARNINGS FOR MAINTENANCE ACTIVITIES ...........................................................1-6
1. 5 REQUIREMENTS FOR CORRECT OPERATION ........................................................1-7
1.5.1 ENVIRONMENT ..............................................................................................................1-7
1.5.2 TECHNICAL SPECIFICATIONS ....................................................................................1-7
1.5.3 WEIGHT...........................................................................................................................1-7
1.5.4 OVERALL DIMENSIONS ................................................................................................1-8
2. CONTROL PANELS ..............................................................................................................2-1
2. 1 THE CONTROL PANEL .................................................................................................2-2
2. 2 LIGHT INDICATOR ........................................................................................................2-6
2. 3 SMEMA ............................................................................................................................2-6
3. MAINTENANCE ....................................................................................................................3-1
3. 1 CLEANING THE SYSTEM .............................................................................................3-2
3. 2 INSPECTION OF THE AIR FILTERS ............................................................................3-2
3. 3 REPLACEMENT OF THE FILTERS ..............................................................................3-3
3. 4 SYSTEM DIAGNOSTICS ...............................................................................................3-3
3.4.1 MEANING OF THE ERROR MESSAGES .......................................................................3-5
3.4.2 ARRANGEMENT OF THE MODULES IN THE ATE RACK ..........................................3-6
3. 5 REPLACING THE PROBE NAIL ...................................................................................3-8
3. 6 REPLACING THE PROBE HOLDER ............................................................................3-9
3. 7 CALIBRATIONS ...........................................................................................................3-10
3.7.1 JOYSTICK CALIBRATION ............................................................................................3-13
3.7.2 CAMERA CALIBRATION ..............................................................................................3-13
3.7.3 ELECTRICAL PROBES CALIBRATION .......................................................................3-13
3.7.4 MOBILE CAPACITIVE PROBE CALIBRATION ..........................................................3-22
3.7.5 POWER PROBES CALIBRATION ................................................................................3-25
3.7.6 STAMPER CALIBRATION ............................................................................................3-27
3. 8 UPS (UNINTERRUPTIBLE POWER SUPPLY) ..........................................................3-30
4. GETTING STARTED ............................................................................................................4-1
4. 1 SYSTEM STARTING ......................................................................................................4-2
4. 2 SELECT A TEST PROGRAM .........................................................................................4-2
4.2.1 Wizard Environment – Start page ....................................................................................4-2
4.2.2 Create a new board ..........................................................................................................4-3
4.2.3 Select a board ..................................................................................................................4-3
4. 3 Translation ........................................................................................................................4-5

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4.3.1 Translation .......................................................................................................................4-5

4. 4 Test program execution.....................................................................................................4-7
4.4.1 TESTING ENVIRONMENT .............................................................................................4-8
4.4.2 AUTOMATIC MODE .....................................................................................................4-10
4. 5 SYSTEM SHUTDOWN .................................................................................................4-11
5. APPENDIX ..............................................................................................................................5-1
5. 1 USE THE HDU RECOVERY UTILITY .........................................................................5-1
5. 2 PC SETTINGS ..................................................................................................................5-1
5. 3 RESTORING THE FACTORY CONFIGURATION ......................................................5-1

LIST OF FIGURES
Fig. 1-1 PILOT V8 : Dialog “System configuration” 1-2
Fig. 1-2 PILOT V8 : Safety devices location 1-4
Fig. 1-3 PILOT V8 : Work area 1-8
Fig. 1-4 PILOT V8 : Front view 1-8
Fig. 2-1 PILOT V8 : Control Panel 2-2
Fig. 2-2 PILOT V8 : Light indicator 2-6
Fig. 3-1PILOT V8 Air filter 3-2
Fig. 3-2 PILOT V8 : Dialog “System configuration, tab “Ate Configuration” 3-4
Fig. 3-3 PILOT V8 : Diagnostic report 3-5
Fig. 3-4 PILOT V8 The ATE Rack 3-6
Fig. 3-5 PILOT V8 SCAFP Module Layout 3-7
Fig. 3-6 PILOT V8 The measuring probe (on the left) and the nail replacer (on the right) 3-8
Fig. 3-7 PILOT V8 : Dialog “System Maintenance”, “Calibration” 3-11
Fig. 3-8 PILOT V8 : Dialog “System Configuration”, “Calibration” 3-12
Fig. 3-9 PILOT V8 OVP Board 3-13
Fig. 3-10 PILOT V8 Setting the Electrical Probe Calibration 3-14
Fig. 3-11 PILOT V8 Dialog “Set Camera X (TOP)” 3-17
Fig. 3-12 PILOT V8 Dialog “Set Camera Y (TOP)” 3-18
Fig. 3-13 PILOT V8 Dialog “Set Camera X (BOTTOM)” 3-19
Fig. 3-14 PILOT V8 Dialog “Set Camera Y (BOTTOM)” 3-20
Fig. 3-15 PILOT V8 Align top and Bottom Cameras 3-21
Fig. 3-16 PILOT V8 Setting the “Mobile Opens Probe” Calibration” 3-22
Fig. 3-17 PILOT V8 Dialog “Calibration Mobile Open Probe” 3-23
Fig. 3-18 PILOT V8 Setting the Power Probe Calibration 3-25
Fig. 3-19 PILOT V8 Setting the “Stamper” Calibration” 3-27
Fig. 3-20 PILOT V8 : Example of UPS 3-30
Fig. 4-1 - VIVA: “Start” page and “Create New Board” dialogs. 4-3
Fig. 4-2 - VIVA: “Start” page and “Select a Board” dialogs 4-4

II
 general

1. GENERAL

This manual provides all the necessary information on the PILOT V8 Automatic system, on the operations
to be performed to test a mounted board and on inspection and maintenance procedures on the system.
Operators are advised to read this manual before starting the test activities.
A technical knowledge of test procedures and fundamentals in electronics is recommended.
The system is configured for in-line operation.

1. 1 USERS OF THIS MANUAL

This manual contains useful information for:

• Operators in charge of testing mounted boards

• Developers of test programs
• Technicians in charge of maintenance operations on the system

1. 2 REFERENCE DOCUMENTATION

This manual is also based on the information contained in the following documents:

• User's Manual of Microsoft Windows™

1. 3 SYMBOLS

To facilitate the understanding of the sentences used to describe the software, we have used the
following symbols:

WARNING Indicates a potential hazard for the operator or the system that could result from
the action described in the Warning.

NOTE: Indicates a note, a recommendation or a point on which readers should focus more carefully.

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The keyboard selection is indicated as follows:

Key 1+ Key 2 = Press key 1 together with key 2.

Key 1, Key 2 = Press key 1, release it and press key 2.

The files are indicated using the following syntax:

File.xml

where “File” generically indicates the file name and “.xml” represents its extension.

Dialogue windows and their components are described by means of the terms described in Fig. 1-1

Fig. 1-1 PILOT V8 : Dialog “System configuration”

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1. 4 SAFETY RECOMMENDATIONS

1.4.1 PROJECT CRITERIA

The system PILOT V8 has been designed and manufactured in accordance with the essential safety
requirements contained in the EMC DIRECTIVE 89/336/EEC (and subsequent amendments) on
electromagnetic compatibility and in the DIRECTIVE 73/23/EEC (and subsequent amendments) on
electric safety.
The compliance with the aforementioned directives has eliminated or reduced hazards to the minimum,
both during ordinary operation and servicing.
The system is manufactured with premium quality components. All components used are thoroughly
tested in accordance with the quality standards set forth in the laws in force.

1.4.2 SAFETY DEVICES

The systems are equipped with several safety devices to reduce operators' hazards to a minimum. It
follows a list:

• Protection panels (P1): to protect the system from environmental hazards and prevent users from
coming into contact with life internal components.

• Protective cover (P2): To prevent users from inadvertently inserting their hands in the work area
during the execution of a program. The program is immediately stopped if the cover is opened during
the testing phase.

• EMERGENCY OFF Button (P3): When pressed, it disconnects the system (PC excluded).

• Magneto thermal relays (P4): A magneto thermal relays respectively protect the system and the
instrumentation. Both relays disconnect the components from the power supply if the absorption
value is above the limit.

• Ground protection circuit (P5): All components that may come into contact with the operator are
grounded to avoid potential hazardous electric shocks.

Fig. 1-2 illustrates the location of safety devices installed on the system

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Fig. 1-2 PILOT V8 : Safety devices location

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1.4.3 WARNINGS AND RECOMMENDED BEHAVIOR

Users should follow the warnings and recommended behavior described in this section to avoid injuring
others or damaging the system during its operation.

WARNING Never perform operations that differ from those specified in the maintenance
procedures described in Section MAINTENANCE of this manual on mechanical
and electronic parts.

WARNING If the equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired. See paragraph 1.4.4
RECOMMENDED USE OF THE SYSTEM.

WARNING Seica S.p.A. shall not be liable for damages caused by operations that are not
compliant with the instructions provided in this manual.

WARNING The introduction of hands and/or other objects into the system may damage it
and cause serious injuries.

WARNING Never lean on the protective frames of the system during its operation.

WARNING When the system is testing, do not introduce into it any object different from the
board to be tested.

WARNING Do not put any liquids into the system

WARNING For cleaning, inspection and maintenance instructions, refer to Section

MAINTENANCE of this manual.

WARNING If the system needs to be moved from the installation site, make sure that this
operation is carried out by qualified and authorized personnel only.

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1.4.4 RECOMMENDED USE OF THE SYSTEM

System PILOT V8 should be used only to test mounted boards. The use of system for applications other
than those described (for example to test boards with dimensions above the set limits or to test parts
containing inflammable fluids or materials) can damage the system and injure users, and is therefore
regarded as improper use for which Seica S.p.A. declines all responsibility.

1.4.5 IMPROPER USE

The use of the system for applications other than those described is regarded as improper.

1.4.6 RESIDUAL HAZARDS

To protect the users and the system from residual hazards, that is from unpredictable risks or from
hazards that cannot be completely eliminated, we recommend users to strictly follow the warnings listed
in paragraph WARNINGS AND RECOMMENDED BEHAVIOR and to follow the instructions given here below.

• Avoid wearing loose clothing or apparel with parts (sleeves, hems,…) that could be clamped or
get tangled during work.
• Avoid wearing ties or scarves.
• Avoid wearing long necklaces, bracelets or rings.
• If necessary, wear a cap to keep long hair out of the way.

1.4.7 WARNINGS FOR MAINTENANCE ACTIVITIES

Due to the complexity and the high technological level of the PILOT V8 , maintenance operations are
classified in detail along with the requirements for the personnel authorized to perform them.

The customer is authorized to carry out the ordinary maintenance operations described in the
MAINTENANCE section of this manual. For different operations, customers should contact the Customer
Service of Seica S.p.A., which will decide whether to provide specific instructions to allow the customer to
carry out the necessary operations directly or organize an on-site inspection.

WARNING Customers must always contact the technical personnel of Seica S.p.A. before
carrying out any operation.

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1. 5 REQUIREMENTS FOR CORRECT OPERATION

To ensure a correct operation of the system, it is necessary to verify that the requirements described
here below are met.

1.5.1 ENVIRONMENT

Temperature: from 15° to 30° C

Humidity: Min. 20% Max. 80%
Floor surface
5mm/m
planarity:
Altitude: < 4000m
Pollution degree: 2
Installation category: II
Class: I

• The power supply should be located at a maximum distance of 5 meters (approx. 6.5 feet) from the
test system and always be accessible to users.
• The electric source should be equipped with a switch situated next to the socket.
• The electric source should be equipped with a ground contact.
• The noise level, measured under the worst operating conditions, is not to exceed 70dbA.

1.5.2 TECHNICAL SPECIFICATIONS

Power supply: 220 VAC/ 50Hz @12A

110 VAC/ 60 Hz @ 24A
Absorbed power Max. 2.5 KW
• PVC 600V. 90°C section . 3xAWG12 for 230VAC
Adaptable with a 60 IEC 309 2P+ 50-60Hz ±15% IP44 220VAC
Power cables (200-250) plug
• PVC 600V. 90°C section 3xAWG10 for 110VAC
Adaptable with a NEMA L5-30P plug
Series 62 IEC 309 2P+ 50-60Hz ±15% IP44 220VAC (200-250)
Power socket:
NEMA L5-30R for 110VAC 50-60 Hz ±15%.
Filtered at 3 μm
Characteristics of the
air: 99.9% of the oil should be eliminated with the air. Air should be dry and have
a condensing temperature of 10 °C
Compressor capacity Min. 300 l/min
Air flow: Min. 20 l/min
Air supply line ID 3/8” minimum
Air inlet 3/8” fitting with GAS threading
Pressure gauge
Min. 6.5 Atm.
settings

1.5.3 WEIGHT
The system weight is 1200 Kg. (1360Kg. with packaging)

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1.5.4 OVERALL DIMENSIONS

It is necessary to maintain a safety distance between the system and possible external equipment to
guarantee a good circulation of air for the electronics on board and to provide sufficient space for the
operators to access to maintenance and inspection points. Fig. 1-3 and Fig. 1-4 show two drawings of the
work area and system layout.

Fig. 1-3 PILOT V8 : Work area

Fig. 1-4 PILOT V8 : Front view

Length: 175cm (444,4’’)

Width: 123cm (312,42’’)
Height:203cm (515,62’’)

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 maintenance

2. CONTROL PANELS

The PILOT V8 Automatic systems have an innovative control panel, which enables the complete control of
the system through a set of soft-touch keys.
The Control Panel located on the right side of the system, is used to switch on/off the system and to
control the camera movements. There are specific buttons used to start/stop the test and the light
indicator that shows the operator the system status.
A set of LED lights on the control panel, help identifying the operating status of the test system.

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2. 1 THE CONTROL PANEL

This section provides a description of the control panel:

Fig. 2-1 PILOT V8 : Control Panel

Buttons Description

The control panel presents a set of soft-key buttons and led status. Below, a short description of their
function and capabilities

BUTTON DESCRIPTION LIGHT

Switches the main MAIN ON = ON
MAIN ON
electronics ON MAIN OFF = OFF
Switches the main MAIN ON = OFF
MAIN OFF
electronics OFF MAIN OFF = OFF

BUTTON DESCRIPTION LIGHT

MOTION Powers motor axes MOTOR ON = ON
ON ON MOTOR OFF = OFF
MOTOR Powers motor axes MOTOR ON = OFF
OFF OFF MOTOR OFF = OFF

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LED DESCRIPTION LIGHT

ATE ON=ON
ATE ON All test system instruments are powered
ATE OFF=OFF
ATE ON=OFF
ATE OFF All test system instruments are depowered
ATE OFF=OFF

SEL: The SEL soft-touch key, allows to activate the second function possibly present on some buttons of
the control panel. If the button SEL is pressed, the F2 led turns on (the LED indicates the current
function enabled).
The F2 function (where available) is reported in white characters on the lower side of the button. Upon
an idle condition of the buttons (3 sec. approximately) the main function (F1) is automatically restored.

According to the LED light (sx, dx) the FIXTURE MODE button allows to manage the
right/left clamps, using the related buttons (FIX UP, for upper clamps and FIX DOWN for lower
clamps). When the button FIXTURE MODE is hold pressed for a while, the LEDs condition
may be as follows:

SX= ON (control of left side)

DX= ON (control of right side)
DX/SX= ON (control of left and right side)

Depending on the light LED on the FIXTURE MODE button, the button FX UP enables to
drive the left or the right side of the upper clamp. When LED is ON, the clamp is open.

Depending on the light LED on the FIXTURE MODE button, the button FX UP enables to
drive the left or the right side of the upper clamp. When LED is ON, the clamp is open

Note: The mobile rail is managed with the joystick, but only when COVER is open and no VIVA dialog
window is active. Move the joystick upwards to raise the upper rail, and downwards to lower the mobile
rail. This function is active only when the safety key is present and set to Debug position.

To open/close the doors of the test system, use the buttons

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LEDs DESCRIPTION

The upper part of the control panel has a set of LED to provide system information. Below, a short
description of the same.

Section SYSTEM

OK: indicates system is ON

ERR: Indicates a communication issue with Main PC, which determines an error condition possibly
affecting the operation of automation

RT: Intermittent, when the system is in good and correct operating conditions

Section ATE

READY: Indicates the test environment (VIVA) active and running. The system is ready for test
execution (waiting for command)

ERR: This function is not currently implemented

TEST: The system is in test stage.

Section AUTOMATION

FREE: Not implemented on this test system

ERR: General condition of automation error. To diagnose the problem, use the second function. Press the
button SEL and view detailed error messages in the section DIAGNOSTIC

LOAD: Not to consider on this test system

R1: Not to consider on this test system

R2: Not to consider on this test system

UNLOAD: Not to consider on this test system

Section DIAGNOSTIC

The LEDs in the DIAGNOSTIC section, indicate TEST messages, provided this diagnostic mode is
enabled in VIVA System Configuration dialog window.

When first function (F1) is active: When second function (F2) is active:

S0: Not to consider on this test system S0: Problem connected to MOTION ON signal

S1: Not to consider on this test system S1: Problem connected to AIR or AIR sensor

S2: Not to consider on this test system S2: Problem on COVER (door-work area)

S3: Not to consider on this test system S3: S3: Not implemented

S4: Not to consider on this test system S4: Not implemented

S5: Not to consider on this test system S5: Not implemented

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DESCRIPTION
It used to raise (UP) and lower
JOYSTICK
(DOWN) the mobile rail height

BUTTON DESCRIPTION
It immediately stops the system (it stops any movements of axes
EMERGENCY and probes), switching OFF the power. The Personal Computer
remains ON

BUTTON DESCRIPTION
START It starts the test
Close the doors of the
test area

BUTTON DESCRIPTION
• It stops the TEST
• It resets the condition
STOP
“insufficient air” caused by a
inadvertently fall of pressure
• Opens the doors of the test area

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2. 2 LIGHT INDICATOR

This indicator is made up by three bulbs of different colors mounted into a luminous indicator
similar to a semaphore, as illustrated in Fig. 2-2. This tells the general status of the
equipment.

Red light: indicates an error condition

Orange light: indicates XY axes movement or access to the test environment.

Green light: after a homing operation, indicates that the system is ready to execute any
operation.

Fig. 2-2 PILOT V8 : Light indicator

2. 3 SMEMA

The Pilot V8 Automatic is equipped with a SMEMA connector, to interface an external loader (optional).
Vertical loader architecture is recommended.
The SMEMA connector/interface is located on the rear side of the system.

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3. MAINTENANCE

This section describes the inspection and maintenance operations to be executed on the PILOT V8
system. Although the pneumatic parts and the linear guides of the system do not require particular
maintenance procedures, there are several operations that must be executed periodically to ensure a
correct system operation, as explained in the following pages.

OPERATION RECOMMENDED INTERVAL…

Cleaning the system Daily
Inspection of the air filters Daily
Filters replacement When the filter is damp
System diagnostics When a problem occurs
Probe replacement When its operation is impaired by wear
• After the replacement of measuring probes
Calibrations (Joystick, probe)
• Periodically, to compensate wear
According to the working environment (normally every 400
Lubrication of the worm screws
hours)

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3. 1 CLEANING THE SYSTEM

Daily inspect the degree of cleanliness of the system and in particular the guides of Y axis. All cleaning
operations should be performed using a vacuum cleaner for the larger components and paper soaked in
alcohol for the smaller ones. Never use compressed air for cleaning purposes to avoid pushing the dirt in
locations where it could interfere with the operation of the system.

3. 2 INSPECTION OF THE AIR FILTERS

The filtering unit, located in the rear side of the system, as shown in Fig. 3-1, is made up by:

• An air tap
• A pressure regulator
• A pressure gauge
• Air Filter

Fig. 3-1PILOT V8 Air filter

To maintain the system in good working order, it is advisable to periodically inspect the status of the
filters. The frequency of inspections obviously varies according to the type of system employed to supply
air to the system. Air containing higher percentages of impurities requires more frequent inspections and,
occasionally, the replacement of the filters. To assess the working order of the filters, close the cock and
unscrew the pots. Filters should appear dry and have a consistent color. The presence of marks may
indicate signs of oil or water. If signs of contaminations are evident, replace the filters and verify that air
is regularly supplied to the system.

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3. 3 REPLACEMENT OF THE FILTERS

To perform this operation, follow the instructions given below and refer to Fig. 3-1.

1. Close the air

2. Unscrew the pot
3. Remove the internal filter and replace it with a new one
4. Screw the pot
5. Open air

3. 4 SYSTEM DIAGNOSTICS

The status of the system can also be checked by running

the diagnostic procedure. To start the procedure, from VIVA

main window, click the icon SELF TEST . The dialog

reproduced on the left is displayed. From this other dialog,
the operator can set several options to check the system.

Section ATE Test:

Option None: No test is performed on the ATE section.

Option Complete: It performs a diagnostic test on all the ATE modules installed and configured, as

indicated in the System Configuration (icon , Folder ATE Configuration). See Fig. 3-2

Option Interactive: The diagnostic program is executed in the interactive mode to allow the user to
select which ATE modules must be checked. At the end of the diagnostic test, the user can store the
diagnostic configuration set and recall it at a later stage.

Option CUSTOM: this option allows to recall a diagnostic configuration stored during an interactive
diagnostic procedure. The button opens a dialog which facilitates the choice of the required
configuration.

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Fig. 3-2 PILOT V8 : Dialog “System configuration, tab “Ate Configuration”

Section Flying Probe Test:

Enable: this field enables to test all the parts not included in the ATE section.

Cover & Fixture: this field enables to check the operation of the protection cover and of the clamps that
fix the board.

Air: this field enables to check the operation of the pressure switch.

Joystick: this field enables to check the operation of the joystick.

Start & Stop: this field enables to check the operation of the START and STOP buttons.

Probes: this field enables to check the motion of the four mobile probes along the Z axis.

Axis: this field enables to check the motion of the four mobile probes along X and Y axes.

Section Options:

Number of Iteration: tells how many times the diagnostic test has been performed.

Field Print Errors: if checked, this field enables to print the results of the diagnostic program

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3.4.1 MEANING OF THE ERROR MESSAGES

At the end of the diagnostics, the system displays the results of the individual tests in a final report, as
shown in Fig. 3-3.

Fig. 3-3 PILOT V8 : Diagnostic report

The table Tab. 3-1 lists the possible corrective actions for the problems detected by the diagnostic test.

MODULE ERROR CORRECTIVE ACTION

LAM Contact Seica’s customer service
(1)
% SH LN 1 CH n (p/65) Replace the faulty relay on Line 1
(1)
% SH LN 2/3 CH n (p/65) Replace the faulty relay on Line 2 and/or 3
(1)
SCAFP % SH LN 4 CH n (p/65) Replace the faulty relay on Line 4
(1)
% OP LN 1/2 CH n (p/65) Replace the faulty relay on Line 1 and/or 2
(1)
% OP LN 3/4 CH n (p/65) Replace the faulty relay on Line 3 and/or 4
FEMTO Contact Seica’s customer service

Tab. 3-1 PILOT V8 Table for corrective actions

(1)
n: indicates the channel number, from 4097 to 4112.
p: indicates the channel number of the board, from 1 to 16.

If the error originates from module SCA FP, it is advisable to try and replace the relays listed in column
“Corrective Action”. To locate the faulty relays on module SCA FP, refer to the layout of the module
shown in Fig. 3-5 and use the report messages as co-ordinates for a two-dimension array, where the line
number indicates the line and the channel number identifies the column. For example, if report message
is:

% SH LN 2/3 CH 4101 (5/65)

it is necessary to replace the relays CH 4101 LN 2 and CH 4101 LN 3. if the message is:

% SH LN 1 CH 4101 (5/65)
it is necessary to replace relay: CH 4101 LN 1.

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3.4.2 ARRANGEMENT OF THE MODULES IN THE ATE RACK

The ATE rack is located in the rear side of the system. Its modules are arranged as shown in Fig. 3-4.

Fig. 3-4 PILOT V8 The ATE Rack

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Fig. 3-5 PILOT V8 SCAFP Module Layout

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3. 5 REPLACING THE PROBE NAIL

When the probe nail is worn out, it must be replaced. To do this, follo the instructions here below and see
Fig. 3-6:

Fig. 3-6 PILOT V8 The measuring probe (on the left) and the nail replacer (on the right)

1. Press the EMERGENCY button.

2. Using a pair of pliers, grasp the needle (A) and remove it from its housing (B).
3. Insert a new needle in the probe housing (B).
4. Using the nail replacer (C) included in the system kit (cod.INSPUNFP-00), pull the needle into the
probe housing until the nail replacer touches the probe housing.
5. Press MOTOR-ON button on the control panel.
6. Perform the homing procedure
7. Perform the automatic calibration (XYZ axes) and then the fine XY calibration.

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3. 6 REPLACING THE PROBE HOLDER

When the probe holder does not hold the nail in it, it is worn out and must be replaced. To perform this
operation, follow the instructions given here below:

Note: The pictures in this page will be replaced)

1). Press the EMERGENCY button on the control panel in order to work safely.
2). Remove the screws (A) using a 2 mm Allen wrench. Remove the cover as well.
3). Disconnect the connector (D) shown in the figure above
4). Remove the screws (E) with a 2.5mm Allen wrench.
5). Remove the probe holder (F).
6). Install a new probe holder
7). Insert and fasten the screws (E) using a 2.5mm Allen wrench.
8). Connect the connector (D) shown above.
9). Put the cover again
10). Insert and fasten the screws (A) with a 2mm Allen wrench.
11). Press button MOTOR-ON on the control panel.
12). Perform the homing procedure.
13) Perform the automatic XYZ calibration and then the XY fine calibration.

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3. 7 CALIBRATIONS

All the probes, as well as all the moving parts installed on the heads of a Flying Prober, should
be occasionally calibrated when the part is replaced, and periodically, in order to guarantee the
best performance.

Typically a calibration must be performed:

a. every time a probe is replaced

b. if the camera has been moved from its original position
c. every time the system is moved from its original position
d. if the system has not been used for a long time.
e. Every time any of the probes appears to be out of its position during the test
f. All the calibrations are carried out using the OVP check-board, hence this board
should be loaded into the system before starting the calibration procedures.

Run VIVA software.

In the page of the Wizard Environment, press and

select the Template

Now from page of System Library press the button .

The system Maintenance dialog will be displayed on the screen.

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 maintenance

Fig. 3-7 PILOT V8 : Dialog “System Maintenance”, “Calibration”

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The tab Calibrations of the System Configuration Environment will open.

Fig. 3-8 PILOT V8 : Dialog “System Configuration”, “Calibration”

Here the operator may select all the options to calibrate the electrical probes and launch the
calibration of the following items installed on the heads:

- Electrical Probes
- Mobile Capacitive Probe
- Power Probes
- Stampers

Note: It is always recommended to perform the Electric Probe calibration first, regardless of
the type of calibration needed. Please refer to the instructions reported in the dedicated
chapters below.

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3.7.1 JOYSTICK CALIBRATION

This procedure checks the status of the joystick and determines the coordinates of its rest position.

1 – Select the “Joystick” Radio Button

2 – Press “Calibrate”

N.B. DO NOT move the joystick during this procedure.

3.7.2 CAMERA CALIBRATION

It is not necessary for the operator to execute this calibration. It is performed by Seica before delivering
the system.

3.7.3 ELECTRICAL PROBES CALIBRATION

This procedure allows to automatically calibrate the measuring probes as compared to XY-Z axes.

1. Insert the OVP board into the work area positioning it as shown in Fig. 3-9.

Fig. 3-9 PILOT V8 OVP Board

2. Close the protective .

3. Select the checkboxes as indicated in Fig. 3-7 (Probes, Z Alignment, X and Y alignment)
4. Press CALIBRATE
5. Follow the instructions on the screen.

NOTE: CHOOSE THE CENTRAL GOLD CIRCLE ONLY, TO EXECUTE THE CALIBRATION.

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In the System Configuration dialog, select items: “Probes”; “Z Alignment” and “X and Y Alignment”
(See fig.3-10):

Fig. 3-10 PILOT V8 Setting the Electrical Probe Calibration

Set the value of field “Check Board Set Area Number” to 2

Select “Probe type” as shown in the picture

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 maintenance

Press the button for each electrical probe installed (Here: 1 and 3”

and press

Follow the instructions on screen and press YES to

continue

Follow the instructions on screen and

press YES to continue

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Check if the position of the probe 1 is

over the central round probing area
of the check-board and press
. Skip the next picture to
continue.
Press if the probe is not in
that area and go on the next picture.

Use the joystick to move the Probe 1

over the central round probing area
of the check board and press
to continue

When the electrical probe calibration has been completed, a dialog will be displayed to perform
the X alignment of the Top camera. (see fig. 3-11)

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 maintenance

Press the button for higher accuracy

Fig. 3-11 PILOT V8 Dialog “Set Camera X (TOP)”

Now adjust the X alignment of the Top camera with the arrows keys

Press to continue

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Another dialog will be displayed to perform the Y alignment of the Top camera.

Press the button for higher accuracy

Fig. 3-12 PILOT V8 Dialog “Set Camera Y (TOP)”

Now adjust the Y alignment of the Top camera with the arrows keys

Press to continue

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 maintenance

A dialog will be displayed to perform the X alignment of the Bottom camera.

Press the button for higher accuracy, then adjust the camera alignment using the

arrows keys

Fig. 3-13 PILOT V8 Dialog “Set Camera X (BOTTOM)”

Press to continue

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A dialog window will be displayed to perform the Y alignment of the Bottom camera.

Press the button for higher accuracy, then adjust the camera alignment using the

arrows keys

Fig. 3-14 PILOT V8 Dialog “Set Camera Y (BOTTOM)”

Press to continue

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Align the Top Camera and the Bottom camera on the same hole on the Check Board.

Use the arrow keys to center the view-finder on the hole for the Top camera

Fig. 3-15 PILOT V8 Align top and Bottom Cameras

Press to continue

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3.7.4 MOBILE CAPACITIVE PROBE CALIBRATION

In the dialog “System Configuration” select the checkbox “Mobile Opens Probe CPM”, then press

Fig. 3-16 PILOT V8 Setting the “Mobile Opens Probe” Calibration”

Follow the instructions on screen and press YES to

continue when done.

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 maintenance

Follow the instructions and press YES

to continue when done.

In the dialog “Calibration Mobile Open Probe” press the button to zoom in for more accuracy

Fig. 3-17 PILOT V8 Dialog “Calibration Mobile Open Probe”

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Use the arrow keys to adjust the alignment of the red circle over the top of the capacitive
probe

Press to save the new X,Y position

Repeat the same steps to align the bottom side of the capacitive probe and press to save the new
X,Y position.

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3.7.5 POWER PROBES CALIBRATION

If the PILOT V8 in use comes with the power probe option installed, please follow this section for specific
instructions concerning the power probe calibration procedure.

In the System Configuration Environment, select the checkbox “Power Probes” (See fig. 3-18) and

press .

Fig. 3-18 PILOT V8 Setting the Power Probe Calibration

Follow the instructions and press YES to continue

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Follow the instructions and press

YES to continue

Press the button to zoom in for more accuracy and use the arrow keys to adjust the
alignment of the red cross over the center of the power probe top

Press to save the new XY position

Repeat the same steps to align the bottom side of the power probe. When finished, press to save
the new XY position

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3.7.6 STAMPER CALIBRATION

In the System Configuration dialog, select the checkbox “Stamper” (See fig. 3-19) and press
.

Fig. 3-19 PILOT V8 Setting the “Stamper” Calibration”

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Follow the instructions and press YES to continue

Follow the instructions and press

YES to continue

In the dialog displayed, press the button

to zoom out and enlarge the view to search the
mark, if it is not displayed

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 maintenance

Center the mark with the red circle using the

joystick or the arrow keys

Press to save the new calibration

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3. 8 UPS (UNINTERRUPTIBLE POWER SUPPLY)

If the test system is equipped with a UPS; it is recommended to check its correct operation.
To check the UPS is correctly operating, do as follows:

1) Cut the mains supply to the test system

2) If the UPS is working properly, the PC will remain ON and the user will have the time to shutdown
the computer properly.

WARNING: Remember that, in the event of a blackout, the UPS will grants some
minutes to shutdown the system correctly, thus avoiding damages.

Fig. 3-20 PILOT V8 : Example of UPS

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4. GETTING STARTED

This section aims to walk the customer through the steps needed and the procedures to be carried out to
test a board correctly.
Further information concerning the features and capabilities of the VIVA software, are available in the
manual “Viva Software for Flying probe systems

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4. 1 SYSTEM STARTING

1. Open the air tap located on the rear side of the system.
2. Set the MAIN-SWITCH on the rear side of the system to “1”.

3. Press the button MAIN ON

4. Press the button MOTOR ON
5. Press the button ATE ON

Note: For system shutdown, repeat the steps described above, from 5 to 1

4. 2 SELECT A TEST PROGRAM

The VIVA Wizard Environment allows to select an existing test program or to create a test program for a
new board. To select an existing test program, follow the steps provided in the following chapterd.

4.2.1 WIZARD ENVIRONMENT – START PAGE

The page “Start” of the Wizard Environment allows to:

• Create and execute a test program for a board through a simple guided procedure indicated by
the wizard itself.
• Select an existing program for execution or to interfere in the steps scheduled for its
development.
• Execute System Maintenance operations.
• Examine the documentation supplied with the system as manuals or help on line.

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 calibrations

4.2.2 CREATE A NEW BOARD

• Enter the Wizard Environment, in the page “Start”, press button “CREATE A NEW BOARD”.

• In the dialog displayed:

o Fill in the fields “Name:” and “Description”. (“Description” is optional)

o Select, from the list of templates available the more suitable one for the kind of board for
which you are creating the test program.

• Press button “OK” to continue; the page “Import Data” is now active.

Fig. 4-1 - VIVA: “Start” page and “Create New Board” dialogs.

4.2.3 SELECT A BOARD

• Enter the Wizard Environment; in the page “Start”, press button “SELECT A BOARD”.

• In the dialog displayed:

o From the list “Boards:” select a board to open a work session.

o If the work session is related to the execution of different programs, and if the system
operates in the in-line mode, the button “Configure Board Loader” allows to configure the
database which identifies the boards to be loaded through the SMEMA interface.
o In the section Board Preview, if available, is displayed the layout for the selected board,
aligned to the data stored in the board database.
o In the list “Boards”, near to field “Name” there’s a field identified as “!” which tells the
program belongs to one of the three possible steps scheduled to develop a test program. It
can also identify a template Database used to develop the test program.

• Prepare
• Verify
• Execute
• Template database to develop programs

NOTE: A “Template” is a sample database where are recorded the default settings used in the Wizard
Environment pages to create a new program. It is important to consider that possible changes
made on a Template database will affect the values of the default settings in the subsequent
executions of “CREATE NEW BOARD” with this Template.
• To continue, press button Select; the page “Import Data” is now available, or the page active during
last program execution.

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PILOT V8 - Operator Manual

• The four buttons “Copy”, “Delete”, “Compress” and “Expand” allow to execute these operations
directly on the selected program with no need to select button SYSTEM MAINTENANCE.

Fig. 4-2 - VIVA: “Start” page and “Select a Board” dialogs

NOTE: If the selected board is a Template”, (e.g. “System Library”) the only page available in the
Wizard Environment dialog, in addition to page “Start”, is the page “Template Option”. This
page allows to define some default settings for some of the attributes used when creating
programs.

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4. 3 TRANSLATION

To test the board in a correct way it is very important to perform a correct translation and marker
setting. The translation procedure is used to reference the board coordinates to the test system and it is
executed by the operator on the first board. On subsequent boards the translation is performed
automatically by the test system with the markers recognition. The details on these procedures are given
here below.

4.3.1 TRANSLATION
• Translating a board means moving all the test points as compared to a specific point of the
testing system referred to as system zero. This enables the system to acquire the position of the
board that needs to be tested and to attain a common reference so that the translation of a probe
has the same value of the translation of the board. Translation is a very important phase of the
testing because if it is not carried out accurately, the probe will not be positioned correctly on the
supports and could yield to a higher percentage of false errors. To attain a correct translation,
make sure that appropriate measures are taken. It is advisable to select the points visually
holding the board sample in order to verify that the points selected are appropriate for testing
purposes. It is preferable to select areas with a squared shape or with limited dimensions as
translation points in order to facilitate centering and limit positioning errors.

It is also very important to select the position of the points on the board, that should be as distant as
possible and in diagonal, as shown in the figure below. It is advisable to avoid the pair 1-2 and prefer,
instead, pairs 3-4 and 5-6.
The following sections describe in detail the recommended steps for a correct translation.

5 4

1 2

3
6

Fig. 3-3-1

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1. If not already opened, press the button to enter the Wizard Environment.

2. Select the Board setup page:

The system displays a window that shows the board layout:

3. Press the . The system will display window Translation.

The translation procedure is

the alignment of the board
reference system to the test
system. In this way the test
system acquires the position
of the board to be tested and
use it as a common reference.
The translation is a very
important test phase
because if it isn’t
performed properly, the
position accuracy of the
probes on the pads will not
be precise with a result of
false diagnosis.

The camera will be positioned

on the co-ordinate of the first
point selected for the
translation, displayed in
window Set Reference points.
The co-ordinate reached by
the camera may not

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 calibrations

correspond to the correct position on the board. In this case, it is necessary to align the two points.
The following step explains how to perform this operation.

4. Position the cross displayed on the center of the selected point. This can be done in three ways:

o Use the directional buttons or the joystick (option) on the Control Panel until the correct position
is reached.
o Keep the left button of the mouse pressed and simultaneously move it in the correct direction to
center the point.
o Position the mouse pointer on the point that has to be reached, then press the right button of the
mouse. The cross will reach the position indicated by the point of the arrow before the pressing of
the right button of the mouse.

5. When the pad center and the pointer are aligned, click on the icon. The system will move the
camera on the second point (defined as TP2).
6. Align TP2 in the same way as for TP1.

7. Press the icon again. The system checks that the coordinates acquired with the camera
correspond to the theoretical points previously selected in the Definition of Reference Points.

If there is an error on the two point distance, the system will give a fail report and suggest to cancel the
operation or to acquire the two values again.

8. If no error is visualized, press the icon to save the translation an then press the icon to
exit.

At this point the translation has been successfully completed and it is possible to continue with the next
steps.

4. 4 TEST PROGRAM EXECUTION

The system can work in two operation modes:

-AUTO Mode
-MANUAL Mode.

This paragraph provides a short description of the test environment and of the two operating modes
available (see below).

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4.4.1 TESTING ENVIRONMENT

1. If not already opened, press the button to enter the Wizard Environment. This page will open

Once you are in the “Run page”, press the button to start the test program.

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 calibrations

Other buttons available in the Run page toolbar are as follows (in brackets is reported the corresponding
command from keyboard:

Start Program (Spacebar) To start the test program for the selected board.

Stop Program (Esc) To stop the test program for the selected board.

Failed Step Only To display a list showing the program executions..

Select a row where the test result is “Fail”; then press
the butto “Start Program”. This will not execute the
complete test program, but only the test (or tests)
which output a “fail” result.

Retry on Error To disable/enable the option Retry on error, to repeat

each test for a given number of times, moving the
probe on the test point. This button is available only in
you have defined the corresponding values in the
section “Retry XY Axis” or “Z Axis Retry” in the Board
Configuration Environment.

Retest Errors To disable/enable the option Retest errors; to repeat

the tests with “fail” result upon completing the test
program execution. If the checkbox “Automatic Error
Retest after Test” in the Board Configuration
Environment is selected, the button is selected. You
may change its status from the Debug Environment.

Stop and retest on Error In case of error, the program is stopped and the
system prompts a dialog to display the information
related to the measurements performed. Besides, the
dialog contains three other buttons , and to
continue the test program execution, end the test
program execution or view the position of the probes in
the work area.

Open the Debug Environment To open the Debug Environment used to verify and
adjust the test program execution.

Open the Repair Station Environment To open the Repair Station Environment used to
identify the components where errors have been
detected (Note: the availability of this environment
depends on a hardware key which can enable the
access to the environment). If the option “RPE or RPSE
is not configured the button is greyed out.

Statistics To display statistics information related to the test

program execution.

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4.4.2 AUTOMATIC MODE

This chapter details the instructions to operate the system in AUTOMATIC mode. To do this, set the key
switch to position “DEBUG/AUTO” like in the picture.

The upper rail motion is motor-controlled. Its position can be adjusted to fit the board size. The operator
can control the system through the operator control panel.

To adjust the mobile rail position:

The upper rail motion is motorized. To adjust the upper rail (mobile) position: press the following buttons
in sequence

1) Press the button to open the doors and access the work area

2) Press Button to enable the control of right/left clamps

3) The LEDS of the button FXUP are ON

4) Press the button JOG to enable the joystick.

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 calibrations

Now, move the joystick UP to raise the upper mobile rail and DOWN to lower the
upper mobile rail.

Close the front door

Press the button START to lock the front door and the STOP buttons to unlock the front/rear safety
door. On “Wait : close fixture” click “Cancel” and ignore the error message.

Click the button START of the RUN page to start the test.

The Pilot V8 Automatic is configured for in-line operation, so the loading/unloading of the UUT is
automatic.

4. 5 SYSTEM SHUTDOWN

1. Press the button MAIN OFF

2. Press the button MOTOR OFF
3. Press the button ATE OFF
4. Exit VIVA
5. Open the air tap located on the rear side of the
system.
6. Set the MAIN-SWITCH on the rear side of the
system to “1”.

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 appendix

5. APPENDIX
This sections provides instructions for the proper use of the HDU Recovery Utilities. Please, read carefully
before you proceed.

5. 1 USE THE HDU RECOVERY UTILITY

These instructions are valid solely to restore the HDU (Hard Disk Unit) to the factory settings.
The recovery will irretrievably delete any data stored in the HDU, so any programme or information
stored in the HDU after the date of creation of the recovery disk will be lost. It is recommended the user
performs a backup copy of the data stored in the HDU periodically, using the dedicated tools, or to save
data on external storage units (e.g. server o external disks).
The HDU allowed for recovery are the same as the factory configuration (same model and type).
Before performing any HDU replacement on the PC, ensure the part is replaced with an equivalent part as
OEM.
Seica S.p.A. declines any liability for data loss caused by the fault to comply with the instructions
included in this section.
It is always recommended to make a backup copy of the Recovery DVD and store it in a safe place.

5. 2 PC SETTINGS
Before performing the system recovery, configure your PC to bootstrap from CD/DVD. Refer to the
instructions provided in the PC User Guide, included in the documentation provided.

5. 3 RESTORING THE FACTORY CONFIGURATION

Restore the system to the factory configuration and settings using the Bootable Image Archive DVD
system specific. Follow the instructions included in the “Seagate DiscWizard™ User’s Guide” or
“Acronis® True Image WD Edition User’s Guide” included in the CD “User Guides for System
Recovery”.

WARNING – Always make sure the “Bootable Image Archive DVD” in use has been produced
for the system you intend to restore; this information is reported on the DVD cover and
identified with S/N (Serial Number) which shall correspond to the system serial number (see
the label on the rear side of your Seica System)
5-2